Homemade Corrugated Iron Roller (well, nearly!)

[@WayOutWestx2]

I learned a lot from this build - and went on to build a better one! Check it out here.. kzbin.info/www/bejne/on_LdqCEqKp_j9E

[@neilels4208]

And so did we learn a lot. Thank you, not for all your hard effort but for taking the trouble to explain everything clearly. Then sharing it all with us. Looking forward to your clear thinking to diagnose and improve.

[@brukernavnfettsjit]

Experiments and learning is never wasted efforts Tim. I really enjoyed your problem solving.

[@antoniorobles8706]

I could't agree more.

[@rodomann]

Exactly! And saved other's time by sharing it! 😂

[@johnhenke6475]

It's never a failure if you learned something.

[@billysmart24830732]

Probably the best video I have seen this year. Definitely not a failure.

[@matthiaswandel]

loving these experiments

[@WayOutWestx2]

Thanks, Matthias. (Why are things so complicated!)

[@VitorMadeira]

Definitely not a failure. This would be one of the best small scale / DIY / home project videos I've seen this year. You learned a lot and we learned with you. This was really great. Thank you.

[@WayOutWestx2]

Thanks, Vitor : - )

[@42lookc]

That was NOT a failure! It was a far better result than 99.9% of us would have come up with! The majority of us wouldn't even try it!

[@fhorst41]

You dont need a LARGE MOTOR. You need a small third cog to reduce to. In other words, you need a Gear Ratio, and a motor strong enough to turn that reduced amount of required torque. I think its probably very doable at 4:1 or 5:1. I look forward to seeing updates.

[@williamolson2441]

Tim, as always, I sincerely respect your 'can do' attitude and willingness/courage to tackle new engineering ideas.

[@WayOutWestx2]

Thanks, William : - )

[@johnmccanntruth]

That was really ingenious! Really impressed with your engineering and building skills.

[@crazycoyote1738]

Blessings for your hard and honest efforts to invent, and share your success and fails. Ppl like you were part of the industrial revolution.

[@RobertMilesAI]

Would gearing down the turning handle help? Obviously the total amount of work would be the same, but it might be much less tiring

[@WayOutWestx2]

Yes, you're right. I just want to sort out the kinks before I spend any more money on it

[@Pterodactyl-kn3ve]

LOVE your ability to think old school. Back in the day they didn’t always have a metal shop or engineer to go to. I am very impressed and it was a great video. Well done.

[@WayOutWestx2]

Thank you!

[@masonheipel]

Thanks so much for sharing your efforts. I've been following the channel for a long while and I'm always impressed with your work. Inspiring stuff, in the shop and in the garden.

[@WayOutWestx2]

Thanks, Mason

[@abbeyomisol]

All I can say, it's amazing how you love your dog.

[@mdi786]

way out guy just made things for me so easy, love you from india

[@racheldavis5229]

You are just a BRILLIANT engineer! I continue to be astounded at what you invent.

[@AndreasHatz]

Building a corrugated iron roller has been on my long list of things to do for years now. Thanks for sharing!

[@Clockwork_Planet]

It wasn’t wasted. It was a superbly entertaining video.

[@AgsiSD]

I love watching your thought process with these projects Tim.

[@cybrdave]

What I like about you the best is that you “do” things. Good for you!

[@supremelandscapes]

The fun and satisfaction of giving it a go, love how you turned up those wooden rollers, there's a lot of work behind the scenes in this video, you could do another one on some of the details. Could you show more of the turning with the square and round bits, thanks Tim.

[@leilanistillwell8661]

Hi ! From California USA ! I see you have some AMAZING candle stick holders in different sizes with the wood you used for this project. The wood grain design caught my eye right away. Beautiful with some stain or clear lacquer... just no steel center 😃 just cut them to different sizes & hollow out the center for a pillar candle. The bulky candle stick holders could go on a fire place mantel etc... let me know what you think ? They WILL be a hot item in your store.. oh.... maybe engraved with some animals or something ? PRECIOUS 💕🙋🏻

[@WayOutWestx2]

Ha!

[@Zortorond]

This is genious! Thank you very much for inspiration! I've never thought about combination of the ring roller and shaped rollers for this purpose! I think you could made the rollers by aluminium casting which can be done in a backyard environment with ease especially for such simple shapes to be cast.

[@otm646]

This is a good start. If you look at commercial rollers the lower pair of wheels are fixed, but jack screw adjustable, in a triangular plate steel frame. Then all you need to do is apply force via bottle jack. It'll take some shimming but you'll get there in no time. As far as input force goes, you simply need a bigger gear reduction. An old compressor motor plus a bit of bike chain and you'll be there in no time. When it's powered you'll be able to make many more cycles thus smaller displacement each cycle. That means even less input torque required.

[@Wilcosach]

Good Work. The more you try the more you get better. That is how i got better. Every failure is a step closer to get better at what you are doing. The first version is never the best. You won't notice it but your mind now get more tuned into building better things. After a while you will notice yourself how far better you've gone.

[@mandylavida]

I am in awe of ALL Tim's projects, working or otherwise!

[@WayOutWestx2]

Aw, thanks, Mandy!

[@johncooper751]

Mini fails are just hurdles along the path to success. Love your thinking and work ;-)

[@wayneenevoldson9365]

To get Curved Corrugated Metal I noted the industry uses two operations....first Form straight Corrugated Sheet...then run the Corrugated Sheet again through a Second adjustable Set of Rollers to obtain required Arch needed!!!! This allows Metal Roofing to obtain/become Free Span Roofs (no Rafters or Roof Structures).....Great Video....Keep Up the Interests

[@katrinat7920]

Gee you put in a great effort. You are so clever to have built the device. Well done.

[@WayOutWestx2]

Thank you! Cheers!

[@robderham1958]

You certainly did a great job creating this contraption, and it actually works!

[@samiamm5764]

Maybe not a perfect roller, but I bet it’s a terrific straightener. I need just that on the ranch. All my animal paddocks are covered in corrugated tin and the wind wrecks them, it’s a constant struggle to keep them in good shape. That machine would fit my needs perfectly

[@YoushaAhmad]

I like that you show all of your projects, not only the ones that went to plan. Great effort. I have seen these planters and large water storage cylinders made of corrugated steel in a circle formation. I am not sure how many pieces they are made up of, however you could use half of one for the roof. If you find a planter/ water container that is 1.2m in diameter you could perhaps cut it up and attach it to two pieces of straight corrugated steel. It wouldn't be the same as one piece but I think it will be an easier option and perhaps more cost effective.

[@WayOutWestx2]

Thanks, but they're not available here at all : - (

[@bigchuckyinkentucky6267]

Once heard of a famous quote by someone that I can't remember. "Try, fail, try again, fail better." If this is not the perfect inspiration for how to ultimately reach your goal, I don't know what is.

[@joshb6993]

Beautiful video mate. Thanks for the taking me on the journey, I love projects like this

[@michaelmcclafferty3346]

Well done Tim. You gave it a good shot.

[@WayOutWestx2]

That was an early version - it's working now..!

[@jasongarland3165]

The tracer lathe was a win in itself. This is one of those KZbin videos that taught me something. Thank you for sharing.

[@watahyahknow]

interesting idea using the square pipe and pieces of ply around it , might work whell for making a thickness sander too

[@WayOutWestx2]

Yes, that's another tool on the list to make

[@jonanderson5137]

I don't recall unsubscribing. Glad to find this channel again.

[@Nighthawkinlight]

So cool to see your last few videos building toward these bigger projects. I think getting a smooth roll without the kinks is probably down to the rigidity of the frame. Rethink that and I think you'd be there. A few more gears and you could get away with using a fairly small motor

[@Nighthawkinlight]

Also, perhaps the corrugations on your rollers are too deep! When I've seen rolled corrugated steel in person it seems the corrugations have been allowed to get shallower along the bend.

[@WayOutWestx2]

Thanks, Ben. The problem is if the corrugations were shallower, then the sheet would be wider, so I'd end up with a pear-shaped piece, wouldn't I?

[@Nighthawkinlight]

Ah yes, right you are.

[@windinwaters6599]

We use what is called tank iron for making mining shaft collars, the metal is softer and does not kink if you run it through a few times to get your desired curl. Newer corrugated iron is more tensile and kinks

[@WayOutWestx2]

I didn't know that when I started, but you're right. Now I just have to find some in Ireland...

[@windinwaters6599]

Best of luck with your project you are certainly willing to give things a go and something good always comes from that. Keep your eyes open for an old caste iron roller and one will turn up, they used them for tank making and bullnose sheeting and are still around unused and needing love

[@ranchoelchamusquito3683]

genious this is absolutley fantastic fren I was looking into how to corrugate sheet metal for a mini niesen hut / iris hut / ww2 hut

[@susanbell2771]

Love experimenting, then contemplating the result then trying again and again, not sure how to solve this one but sure you can find a way

[@timdyck8492]

I don’t think failure is a word anyone should ever use ,it is trying to figure something out and it is always improved upon till it works ,and I know you can use a cheap little motor with some pulleys and belts to make a gear reducer then the motor doesn’t need the torque , nice job and that’s what I do too ,take a break from a project until revelation comes !!👍

[@samb8414]

You have such a delightful voice and a fantastic approach to making things. I adore your work please continue to make such marvellous videos xo

[@WayOutWestx2]

Thanks, Sam : - )

[@barrybrady6814]

Fair dues to you for trying you made a great attempt I ve have often taught how to do this as there is numerous thinks you could make

[@hesperhurt]

I used to work for Corus in their profiling division. Curved sheets are/were part formed then full formed within the curving press. The change to peak and valley structure holds in the curve and reduces creasing. Lubrication is also key. It reduced deviation, creasing and splitting. Your design is fine... but: A. Make the form 1-2 degrees more extreme than the formed sheet. B. Roll half sheets: even the commercial equipment is cheaper at 1/2 sheet form factor because it's so much easier. C. Use a pre loaded rope drive and a vehicle winch to rotate the rollers. D. Multiple passes at fractional increases are vital. A 180 sheet on our standard hydraulic units was 5 passes. Only the "beast" that used a pre and process heated system formed them in 1 hit.

[@WayOutWestx2]

Thanks, Robert. Actually I made 40 passes to get to these curves! I have a new idea though...

[@hesperhurt]

@@WayOutWestx2 Ouch! 😂 Look forward to seeing it. Honestly... look at some of the stuff they do over in Africa. Saw a father and son team making steel drums using an old truck driven axle as a metal spinning lathe and seam welding with a bank of 10 car batteries! 😳 Mother of invention and all that 👍🏼

[@sharonoleary9935]

Those wood rollers were beautiful, really works of art!

[@Cellottia]

Beautiful patterns on the turned wood rollers. Make more, finish them really nicely with sealant or lacquer or whatever, and sell them as art pieces to fund the project 😀

[@dfabeagle718]

table legs!

[@KravchenkoAudioPerth]

As mentioned below I vote for a geared down solution. And perhaps rounding out the rollers that are missing their nice round bits. That may be the source of your ripples in the sheet stock of the ripples are at a regular place in the finished profile. Great job! And thanks for taking the time to make this video. You are much closer to your goal than you think.

[@WayOutWestx2]

Thank you! (No, the flat tops didn't line up with any of the kinks - interesting.)

[@BrainStormAcres]

We love watching your experiments and builds. Been watching for a long time, and enjoy your thought process!

[@slowdaze]

You can make gears, is there a way to provide a mechanical advantage to the handle via a chain and gear instead of direct drive? You will have to complete more turns, but they will be easier.

[@jerrynix5206]

Very cool I've actually been looking for somewhere to buy just those rolled corrugated sheets. Well done sir!

[@alastairchestnutt6416]

Always interesting to see your new ideas. The problem seems to be the enormous forces involved to increase the curve. This is a hugh stress on the frame and you as you try to turn the handles.

[@mdouglaswray]

Fascinating! I would have never thought of wood rollers!

[@nigelw598]

Hi Tim, I’m watching with interest in Australia. I salute your ingenuity and perseverance, well done Sir, Cheers, Nigel 🍻

[@WayOutWestx2]

Thanks, Nigel : - )

[@tropifiori]

Brilliant attempt- I enjoyed watching. I have no idea how to improve it, but good luck with the next attempt.

[@WayOutWestx2]

Thanks, Frank!

[@Khamomil]

At least you ended up with great looking rollers. Maybe you could use them for rolling corrugated pasta, or as sculptures? The wood grain looks terrific.

[@sgtjitters8980]

I’m no engineer, but it looks like you can benefit from having a couple of gear ratios, if your arms are hurting and stuff like that I’m pretty sure doing something with ratios and gears would be able to help on that front

[@bluelilly6124]

You are one true genius, you made it very easy and affordable thing and thats too in wood. ...👍👌👏👏👏

[@lv_woodturner3899]

Interesting video. The tighter the radius, the more likely to get kinks. The rolling of the flat bar worked well. How about rolling a few pieces of flat bar to make a set of ribs, then covering this with sheet steel or plastic screwed to the ribs. It is much easier to get the tight radius you desire with such a construction. A less expensive method may be to make the ribs from PVC pipe. You would likely need to heat the pipe to get the tight radius, but you could make a template of the shape then heat and bend to the template a lot easier than rolling steel. Dave.

[@WayOutWestx2]

Thanks for the suggestions. I hope one day to be able to show you why I'm holding out for this design..

[@mccc4559]

I'm proud of your effort bro. Also, I enjoy your style and manner of speaking!!!!

[@johnschuster9192]

So the best way is to walk away brush off your hands and your injured self worth and do something you know how to.. Then overnight or a few days or weeks take another whack at it..I watched the guys with all the money to buy the correct machinery make some roofing material.It wasn't done in one roll through but several.Keep after it and thanks for showing us all your wit to go ahead with this project...great job..

[@philliplopez8745]

The shelter is a good idea , but you need to turn the corrigations 90° . Go with the flow .

[@mmanut]

I think you are almost there, don't give up‼️👍👍. Vinny 🇺🇸

[@ashleygill5040]

Hi Tim. I like you idea. If the house has a curved roof with ends does the sheet need to be corrugated? Plain sheet should be plenty strong enough at this size.

[@WayOutWestx2]

You're right and I might end up doing it that way - but it doesn't look as good : - )

[@RobbsHomemadeLife]

I wasn't going to watch this. I live in a 1 bedroom apartment in a city with no room for rollers,LOL. but I am glad I did. I loved the idea even if it did not work %100. I was impressed when you switched from steel rollers to wood. so many people only know how to get to no, they never keep searching for yes. You did. I wonder if you could try a different material for the roof. it is brilliant to come up with new uses for pallets. There is a wonderful old book by ken kern titled The owner built home. it is crammed full of amazing old technology for alternative home building methods. On one of the pages was a design for Quonset type homes made from mostly cloth covered frames that were hoop-shaped and the cloth was permeated with a cement slurry. When the cement dried it created a strong roof and walls that was in a corrugated hoop shape. I wonder if you could make some hoop frames and cover them in burlap and add the cement slurry to them?

[@porkdemon]

interesting, cool that you could create the actual rollers out of ply, and they look kinda nice as well, almost like timber damascus with all the layers showing through. Gear ratio for the hand crank? maybe mess around with increacing the ratio of turns of the crank to turns of the rollers? idk how it would work with something that size though. Can you hook up a bike somehow? i feel peddling might be a lot easier than cranking by hand, leg muscles being a bit stronger and all.

[@maehay4065]

I suspect that you will come up with what will work for you eventually Tim. I love your prototypes!👍

[@mike-vg6hl]

I’m subscribing here just because your “failure” video, it’s amazing.

[@250-25x]

I have often found the ability to do most any shop task can sometimes be a hindrance. Outsourcing some work saves time and money sometimes......GREAT engineering there on a tough build... G>

[@WayOutWestx2]

Thanks, Gerry. You're quite right - 'I wonder if I could make that myself' is a dangerous thought : - )

[@gregzambo6693]

I work for a company that does this by expensive machines every day. You have done well with minimal equipment.

[@adshwartz]

Ive seen a machine like yours and they had the same issues, in order to solve that they've put 4 rollers on the top and 4 on the bottom and each couple had a bit more pressure on the shit so the stress on the machine was spreaded between all the rollers. It worked really good but it did not solve the curve issiue and worked only for flat pannels It is possible to build a multiple roller machine that the relationship between the rollers is chaning progressively so as the sheet is being corrugated its being curved at the same time, but that is adding way more complicity to the machine and deammand gear and chain system to time all of the moving parts together...

[@antonioalvarado2362]

Very creative I love this idea, a lawn mower motor idle down would help to control the speed, or an old go cart motor. Just press the petal to control the speed..or a beefeater, but a weeder might not be strong enough.

[@drekfletch]

The only thing I can think of that might help is heat. You're curving the corrugations across the grain, which is where it's stiffness comes from. You're compressing one ridge, and stretching the opposite valley. The result is many inches difference in length. F'ex, at 36" interior half circle at a 1" ridge/valley will be a total of 6" longer on the outside than on the inside. What you're rolling looks almost 2", which is a whole foot difference. Heat would help ease the expansion and contraction. Though it might damage the rollers...

[@TheMrWoodsman]

Well done for the effort, time for a rethink.

[@johnmcdyer7297]

Fair play for you Tim I said it before and I say it again,there’s more in your head than you take out with a comb,,

[@WayOutWestx2]

Ha! Thanks, John : - )

[@cereus57]

If you don't try you'll never know, but that was an exceptional attempt!

[@AndreS_-df2nw]

You need rigidity of the rollers( like the heavy ones shown on that industrial one you pictured.) Then you also need guide plates to keep the material straight entering & exiting the rollers.

[@philbox4566]

I have a couple of corrugated iron curvers. Both of them motorised. One is a very very old set and one a newer set. One thing worth mentioning is that if you do not use corrugated iron that has been made for curving then you will have major problems. There are two types of corrugated iron. High tensile and soft feed. The high tensile corrugated is much thinner than the curving quality iron. In the old imperial system the gauge for curving quality iron is 24 gauge. The high tensile is 26 gauge. In the new money the curving quality is .65mm and the hi tensile is .42mm. You can curve the hi tensile but you can only slightly curve it. The curving quality iron can be curved down to a 350 radius if you have the correct rolls with very close bottom rolls. So you are on the right track. You should check though that you have the correct material to start with. I am in Australia in Queensland where we have a lot of curved roofs. Not sure if you can get soft feed curving quality corrugated in pommy land though. Hope this helps you in your quest. Personally I think you've done a great job with limited materials and knowledge of the subject. I do think though that you need steel rolls to do what you need. You will also need a very rigid frame.

[@WayOutWestx2]

Thanks for this, Phil. I'm trying to find someone here who even knows what I'm talking about. Perhaps it just doesn't exist here..

[@philbox4566]

@@WayOutWestx2 I assume you are in England. It's fascinating to me that the home of where corrugated iron came from has more or less lost the knowledge of how to use those materials. Surely some company will know something about what you require. Perhaps ask some of the roofing companies.

[@WayOutWestx2]

Ireland

[@dalemanolas5994]

@@WayOutWestx2 Phil is absolutely correct about the two grades of sheet. However you've still got a fascinating experiment there. Maybe try is to heat the sheet as much as you can before attempting to roll it. The colder the metal is then the harder it will be to curve and the more likely it will be to kink. A bit of heat might make it easier and give somewhat better results. I also wonder how you'd go forming with that rig. Maybe try finding some really seriously thing scrap aluminium flat sheet and running it through. Cheers

[@bikefarmtaiwan1800]

That was an amazing achievement! No mean feat to get to that level of corrugated sheet bending. For what it is worth I'd suggest that - once it is motorized- that you make smaller adjustments for each pass through the machine. Gradual deformation will help reduce the kinks. The video style was fun. The turned ply looked lovely too.

[@WayOutWestx2]

Thanks - but check out the latest video in this series - I've made some progress!

[@NathanNostaw]

The old school galvanised iron was much softer than the zincalume or colourbond sheeting we get now. The softer iron would have worked in your machine, but the new stuff is just way to hard. Thanks for sharing, was a good interesting video.

[@WayOutWestx2]

Thanks, yes that makes a lot of sense

[@randytucker3083]

fine work. My work almost never works on the first go. Fun to watch

[@rickybailey7123]

That was perfect thank you wow I never even thought about wood !!!🙂👍

[@florascent9ts]

1) gearing and 2) how feasible is it to bend thinner strips and rivet them together?

[@craigriglin]

I had the same idea. I figure wood would work ok. I didn’t have the nerve to go through with the idea. I’m glad to see that somebody did.

[@bricklearns]

Steel plate frame to hold everything together? Better bearings?

[@WayOutWestx2]

Possibly. But the second set-up was very rigid, so perhaps it's something else?

[@Steelandbrass]

Heating the steel to anneal it before you try to roll it may help a little by making it softer or you could try smaller pieces and then weld them all together.

[@dennismayer4936]

Thanks. For the effort and honesty!

[@widdershins2687]

Could you add some Henry and/or Flora power to turn the handles?

[@8billionviews752]

Got a lot of ideas from this video. Thank you for sharing

[@timcoppinger1361]

Absolutely brilliant. Well done.

[@shanek6582]

Wish you lived in America near Tennessee, we’ve got those trees on our land you could use. Even a bunch of Osage orange and black locust.

[@WayOutWestx2]

Perfect!

[@oneshotme]

And now you see why they cost so much huh? :) Enjoyed and gave a Thumbs Up also

[@shahidsi2089]

I liked your video. I need a Corrugated Iron Roller for my project. So far no luck.

[@OctopusGardenFarm]

What a great idea! I love your machine you are so inventive. Have you ever thought about doing a cheaper model with corrugated plastic and PVC piping for ridging/supports. At least it would be a cheap mock-up/visual even if it's not as effective. Hope you're able to work out all the kinks in your machine, I'm sure plenty of people would purchase these from you.

[@WayOutWestx2]

Thank you : - )

[@michaelsimpson9779]

Yes, most corro these days is high tensile, you need what is called a soft coil feed to successfully get bull nose or tight radius curvature........ 20 out of 10 though for the solid effort getting to where you did. Awesome work.

[@WayOutWestx2]

thanks, Michael. Just need to find some now..

[@StevesProjects]

Good effort and an interesting video.

[@jrwdeere5416]

I admirer you effort now i now not to try to roll corrugated steel

[@AtulSohan]

My Good Sir, its never a waste..... iam a trained engineer and i would not have thought of using the wooden rollers, Thank you for that

[@Rubensgardens.Skogsmuseum]

Most trained engineers do not think of anything.

[@AtulSohan]

@@Rubensgardens.Skogsmuseum very very true. the thoughts are bound

[@WayOutWestx2]

Thanks, Atul. I'm a carpenter/beekeeper really so I look for wooden solutions first

[@bossecarlberg]

Hi Go down in thickness of the plate .4mm is en of I have roof with .4 mm thickness and the profile is the same as you try to make but the kinks is difficult to over win. I hope you understand my English Im from Sweden

[@WayOutWestx2]

The thinnest I can buy here is 0.6

[@bossecarlberg]

@@WayOutWestx2 Wath is the thickness of the plate you test with ? wen I look on the video its seems 1 mm or more

[@WayOutWestx2]

It's called 0.6mm - perhaps that's the thickness before they add the zinc?